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How to make the melting process of electric furnace save energy

Author : Hongteng Time: 2022-05-31

In the metal smelting industry, induction furnaces are widely used. In actual production, the rational use of electric furnaces is of great significance to the entire production line, especially in improving the production efficiency of the production line and reducing energy consumption.

Today, the editor of Hongteng will summarize with you how to use the smelting process of electric furnace to save energy.

The first is the need to properly handle the charge in the furnace. The charged charge must be properly classified according to chemical composition, impurity content, block size, etc., cutting large and long scrap, and conditionally handling light and thin materials to ensure smooth charging.

The size of the filler block should be adapted to the frequency of the power supply. The power frequency used by an induction furnace decreases as the furnace capacity increases. The penetration depth of the induced current matches the geometry of the metal charge.

This work can shorten heating time, improve thermal efficiency, and reduce power consumption. Avoid delaying the smelting time of the whole process due to unqualified filling material components, increasing material consumption, power consumption, and even scrapping molten steel.

At the same time, we should try to extend the continuous smelting time. The unit consumption of electric energy has a lot to do with the smelting method. According to the data, considering the energy loss required for slag melting and overheating, the unit power consumption of the advanced intermediate frequency induction melting furnace is 580kw*h/t during cold start. When the hot furnace is operating, the unit power consumption is 505-545 kw*h/t, and if the continuous feeding operation is performed, the unit power consumption is 494 kw*h/t.

Therefore, when conditions permit, centralized continuous smelting should be arranged as much as possible, one smelting heat should be increased as much as possible, the continuous smelting time should be prolonged, the number of cold furnace smelting should be reduced, and power consumption should be reduced.

Another aspect is that we need to use reasonable pre-furnace operation techniques, such as controlling the amount of subsequent charge for each temperature rise, and after the molten steel is transferred to the ladle, an appropriate amount of heat preservation agent and slag remover should be put in in time, which can reduce steel production. The loss of liquid sedation in the pouring process can be appropriately reduced to save power consumption.

In the smelting operation, the temperature is raised for a short time before pouring, and the molten iron is kept at a lower temperature in the rest of the time, which can reduce the erosion of the high-temperature molten iron on the furnace lining, prolong the service life of the furnace lining and reduce power consumption.

Finally, we can save electricity and reduce consumption by strengthening the management and maintenance of furnace equipment. Standardize the operation process requirements of furnace building, oven, sintering, smelting, etc., and strictly implement the maintenance system of the power supply, so that the furnace age can be effectively improved, the normal operation of the electric furnace can be ensured, and the power consumption can be reduced.

This is our knowledge sharing today about making the electric furnace melting process more energy-efficient, I hope it can be helpful to you.

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Video of the use process of the furnace

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